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ALUMINIUM RoLLINg INDUSTRY Rusal – largest producer of aluminium foil in Russia UC Rusal, a leading global aluminium producer, is also Russia’s largest producer of aluminium foil and packaging materials made from aluminium foil. The Packaging division comprises four foil mills: Sayanal, Armenal, Ural Foil and another plant under the brand ‘Sayanskaya Foil’, where household foil is rolled and packed. Rusal’s Packaging division mostly produces household and technical foil, converter foil and foilbased packing materials. At present, the Packaging division makes 81,000 tonnes of aluminium foil a year. By 2016 Rusal plans to invest USD17 million to increase production to 100,000 tonnes a year. Coil transport at the Sayanal plant Packaging materials made from aluminium foil are in high demand all over the world. Typically, the higher a country’s standard of living, the higher the demand for aluminium foil for packaging purposes. Analysts at BrookHunt predict that by 2025 the amount of aluminium used for packaging in developed countries will have increased by nine million tonnes, compared with the 2010 level of 5.5 million. Converter foil Converter foil is the Packaging division’s most promising product as it delivers much higher margins than conventional household foil. Converter foil is used for easy storage and packaging of goods such as food, pharmaceuticals and cosmetics. Alufoil is the perfect material for preserving the taste and freshness of dairy products, juices and baked good. Based on Rusal’s estimates, converter foil accounts for 60% of the world market. Rusal is planning on coupling an increase of overall production in the Packaging division (from 81,000 to 100,000 tonnes) with a shift in distribution to converter foil (from 30% of total production to 50%). Household foil The improving economic situation in Russia has resulted in the consumer demanding higher standards in their basic household goods. Russian consumers begin to prefer ecofriendly and healthy goods to those that are cheaper but less safe for themselves and the environment. This trend can also be seen in the household packaging materials market, which has led to an increasing demand for foil. The Russian household foil market has been growing steadily both in scale and volume. ‘Sayanskaya Foil’, produced by Rusal, has become the most popular household foil brand © Rusal due to its high quality and product diversity. Household aluminium foil strip comes in all shapes and sizes, making it very versatile. Depending on the foil thickness (9, 11, 14, 20 µm), it can be used for storing or preparing food at a widevariety of temperatures. The strip width is specially designed to fit in standard-sized stoves. The bobbin length varies between 8 and 100 metres. Household foil is produced at the ‘Sayanskaya Foil’ plant in Moscow region, while aluminium strip comes to the factory from Rusal’s foil mills for rolling and packaging. Then the finished product is ready for sale. On the B2C market segment for household foil, Rusal’s owns proprietary trademarks ‘Sayanskaya’ and ’Sayana’. Under the brand name ‘Sayana’, Rusal offers cling film, baking paper and roasting sleeves and foil for hairdressers. Rusal, according to in-house analysts, accounts for more than 50% of the domestic household foil market. Not only does Sayanskaya Foil make its own products, it also provides custom labels for world-famous retail brands operating in Russia. Rusal’s production facilities The Sayanal plant is the most technologically advanced of Rusal’s foil mills. It is located next to the Sayanogorsk and Khakas aluminium smelters. Sayanal was built in 1993 with the support of the Italian engineering company Fata and the US company Reynolds Metals. This is Rusal’s sole foil mill which produces decorative foil, laminates, paperbacks, multicoloured prints, lacquer coating and colouring. Sayanal’s design team customises foil to fit the clients’ needs. Between 2008 and 2010 the plant started producing new kinds of foil and packaging materials: plain 5 µm foil for capacitors, a special aluminium strap for the production of wainscotings, multilayer composite foil for sealing food products and coloured paper-backed foil for the tobacco industry. In 2011 Sayanal produced a small amount of foil (4.5 µm) for a Russian capacitor factory; 4.5 µm is Rusal’s thinnest foil at present. Rusal is implementing a multi-faceted facility upgrade at Sayanal to increase the plant’s capacity from 38,000 to 42,000 tonnes a year and also improve product quality. In September 2011, the thickness gauge for mill B1 was replaced, and the thickness monitoring system and strip profile were upgraded. An upgrade of the C32 mill finish is planned for 2014. The foil mill Ural Foil will increase production levels from 16,000 to 24,000 tonnes a year. This plant is an important pillar of Rusal’s packaging business and one of the fastest growing facilities in Russia. Ural Foil was built in 2003 as part of Mikhailovsk non-ferrous metal working plant. The direct rolling mill ABP 1600 was upgraded and commissioned in 2013. Planned plant upgrades include: debottlenecking in the casting blank production area; modernising the cutting machine and equipping it with a lubrication unit for container foil production and purchase of a foil annealing furnace; retrofitting of the direct casting unit ABP 1600; purchase of a modern cutting machine for foil with a thickness of 0.005-0.05 mm; and the purchase of two foil annealing furnaces. The management is also planning to conduct a partial upgrade of the automatic process control system for the Quatro 1800 roughing 26 ALUMINIUM · 11/2013
SPECIAL ALUMINIUM RoLLINg INDUSTRY mill and Achenbach foil mills. In the next two years a new gas engine generator plant (14 MW) is to be constructed at Ural Foil. For consumers in aviation, construction and the electrical and pharmaceutical industries, the company recently introduced a new product: foil, 0.12-0.18 mm in thickness, which is used for the production of heat exchangers and automotive radiators. Rusal’s foil mill Armenal is the sole foil producer in the Caucasus and Central Asia, and one of the most modern and ‘green’ mills in the world. It was built in May 2000 as part of the Kanaker aluminium smelter. Achenbach from Germany carried out upgrades to the facility from 2004 to 2006: the installation of latest equipment allows Armenal to provide for the full production process on its premises, diversify its products and ensure the highest quality of its goods. In 2009 the factory began production of household foil (12-22 µm), which is in high demand globally. Soon the plant will work on further mastering thin foil technology. In 2010 the foil mill deployed a new machine for foil cutting and bifurcating and installed a new Seco / Warwick furnace. The new equipment contributes to further improve the quality of Armenal products. In order to increase efficiency, the management plans to install an Achenbach system in 2013-2014, which will capture and distill fumes as well as generate Airpure-Wor lubricating and cooling liquid. The smelter will be equipped with an additional transformer substation and cooling towers. In the cutting and annealing works the cutting machine will be upgraded and equipped with a lubrication unit for the production of container foil. The packaging area will receive a new chamber for timber drying. Armenal’s production is set to rise from 26,000 to 33,600 tonnes a year, on par with the overall increase at the Packaging division. Sayanskaya Foil was founded in 1997 in order to utilise foil waste from Rusal’s Sayanal foil mill. Two years later it was relocated to the Moscow region to streamline logistics and enhance customer relations. All the equipment at Sayanskaya Foil was supplied by Ludwig Brucher from Germany. Since 2010 Sayanskaya Foil has been working to increase production capacity and improve product quality. Upgraded equipment along with operational standardisation have led to an increase in production from 16,000 to 23,000 unites per machine. Since its inception, Sayanskaya Foil’s product range has increased five-fold, and its output has increased by 40 times. Year after year the company broadens its product range by 1-2 products. Last year plant production reached almost 2,600 tonnes; this year output is expected to grow by 7.5%, reaching 2,800 tonnes. Sayanskaya Foil has a yield ratio of 99.6%, making it a highly efficient facility. Technology centre In June 2011 a technology centre in Sayanogorsk was founded under the auspices of Rusal’s Packaging division. The centre is focused on finding solutions to issues related to standardising foil production, consolidating and analysing data, selecting and implementing the best methods and professionally training employees at Rusal’s foil mills. The centre also tests new technologies and works on its further implementation at Rusal’s facilities. All of Rusal’s foil mills can gain certifications in accordance to international quality and environmental standards thanks to the technology centre’s work. These ‘umbrella’ certificates help limit the company’s audit expenses and monitor product quality. Today, all of Rusal’s Packaging division facilities are certified in accordance to the ISO 9001 international quality standards. n Millmate Thickness Gauge. Lab accuracy in the mill. With more than 150 installations worldwide the MTG has shown its reliability and exceeded our customers’ expectations. The green PEC measurement technology is environmentally-friendly, providing personal safety and totally eliminating the hazardous drawbacks of systems based on isotope or X-ray sources. MTG works impeccably in the toughest of environments and there is no need for calibration and alloy compensation inherent in older technologies. MTG is more than a thickness gauge and has several extra features including reliable clad measurement and a unique on-line measurement of electrical resistivity. www.abb.com/pressductor ALUMINIUM · 11/2013 ABB AB Force Measurement Phone: +46 21 32 50 00
Page 1 and 2: © Achenbach SMS Meer Special: alum
Page 3 and 4: editorial Volker Karow Chefredakteu
Page 5 and 6: Contents Advanced casting research
Page 7 and 8: NeW s IN B RIef european Aluminium
Page 9 and 10: NeW s IN B RIef senaat and Ducab in
Page 12: W IRtsCHAft Produktionsdaten der de
Page 15 and 16: eCoNoMy structural and chassis comp
Page 17 and 18: eCoNoMy lysematerial erweitert Trim
Page 20 and 21: economy 40% ownership of Awac), Hyd
Page 22 and 23: economy the engine and wheel market
Page 24 and 25: economy In the limelight - the Arab
Page 28 and 29: ALUMINIUMwALzINDUSTRIE KunShan Alum
Page 30 and 31: ALUMINIUMwALzINDUSTRIE Betreiberman
Page 32 and 33: ALUMINIUM RoLLINg INDUSTRY Ort für
Page 34 and 35: ALUMINIUM RoLLINg INDUSTRY Siroll A
Page 36: ALUMINIUM RoLLINg INDUSTRY Kobe Ste
Page 39 and 40: SPe CIAL ALUMINIUM ROLLING INDUSTRY
Page 41 and 42: SPe CIAL effizienz zu steigern als
Page 51 and 52: Novelis PAE Expert in Casthouse Equ
Page 53 and 54: SPe CIAL ALUMINIUM RoLLINg INDUSTRY
Page 55 and 56: The difference between ordinary and
Page 57 and 58: SPe CIAL ALUMINIUM RoLLINg INDUSTRY
Page 59 and 60: TeChNoLogY Advanced casting researc
Page 61 and 62: A PPlicA tion Ball Packaging bringt
Page 63 and 64: coMPAny news worldwide Aluminij pro
Page 65 and 66: coMPAny news worldwide the amount c
Page 67 and 68: PAtente Patentblatt september 2013
Page 69 and 70: suppliers directory 1.4.1 Anode bak
Page 71 and 72: suppliers directory 1.14 Aluminium
Page 73 and 74: suppliers directory ernSt reinHArdt
Page 75 and 76: suppliers directory 3.4 Hot rolling
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suppliers directory SMS Siemag AG s
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suppliers directory Gautschi engine
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